Comprehensive Cost Modeling and Analysis for a Lean Additive Manufacturing Unit at Sandvik

Sammanfattning

This thesis project performed at Sandvik Additive Manufacturing Division, Sandviken is concentrated on three main objectives. The first objective is to develop an overall cost estimation model for a product manufactured through Additive Manufacturing. The second objective involves establishing Key Performance Indicators on the manufacturing shop floor concerning both Production and Quality. The third and final objective is on developing a lean flow for the Additive Manufacturing production system. Estimating the overall cost of a product plays a very important role in evaluating an organization’s expenses and estimating the company’s yearly budget. Further, estimating the overall cost also helps in deciding the selling price of the product which allows the company to make the right amount of profit on every product sold. Hence, this project provides a comprehensive cost estimation model for a product manufactured in an Additive Manufacturing Unit, particularly for a product manufactured in the Quad Laser Printer considering the complete manufacturing process chain. Now, concerning the Key Performance Indicators, Key Performance Indicators provide a basis for both operational and strategic improvement of an organization. Key Performance Indicators help an organization in understanding the present condition, setting future goals, and more importantly understanding the progress in the quest to achieve the intended result. Therefore, this project presents a hierarchical KPI monitoring structure for both Production and Quality aspects of manufacturing considering the operations of an Additive Manufacturing Unit. Lastly, with regards to Lean Manufacturing, Lean Manufacturing helps in identifying the wastes on a production shop floor and further helps in improving the efficiency and productivity of the manufacturing system by eliminating the wastes. In this project, a value stream mapping tool is employed to understand the present conditionand establish lean flow in the manufacturing system and improve the production lead time of the products.